A refinery was cited by OSHA for five repeat and three serious violations for continuing to expose workers to hot surfaces of refinery process equipment, falls from heights and other hazards at its crude oil refinery. Proposed penalties from this February 2014 follow-up inspection total $184,800. The five repeat citations, with a penalty of $170,500, were issued for failing to ensure that:
- Workers were protected from contact with hot surfaces of refinery process equipment.
- Floor grating in the processing unit was secure and level.
- Ladder floor openings and open-sided floors were guarded to prevent falls from heights.
- Electrical equipment and wiring were maintained in a safe condition.
Three serious violations, with a penalty of $14,300, were cited for failing to ensure anchoring of posts and framing for fall protection railings were complete and effective; to ensure floor holes in walking and working surfaces were guarded or covered; and to ensure metal fan blades were guarded effectively. A serious violation occurs when there is substantial probability that death or serious physical harm could result from a hazard about which the employer knew or should have known.
Citation 1 Item 1
Type of Violation: Serious; $5,500
29 CFR 1910.23(e)(3)(iv): The anchoring of posts and framing of members for railings of all types was not of such construction that the completed structure was capable of withstanding a load of at least 200 pounds applied in any direction at any point on the top rail.
The employer does not ensure that the anchoring of posts and framing of railings was completed and could withstand at least 200 pounds of a load. This violation was observed on or about February 13, 2014, on the 3rd floor of the Fluid Catalytic Cracking Unit (FCCU) where employees were exposed to a fall hazard when the railing of the stairwell to access the floor was not completely anchored in place and was not secure.
The employer must submit documentation describing the steps that is taking to ensure railing is anchored and capable of withstanding a load of at least 200 pounds.
Citation 1 Item 2
Type of Violation: Serious; $4,400
29 CFR 1910.23(a)(8): Every floor hole into which persons can accidentally walk were not guarded.
The employer does not ensure that all floor holes are guarded, exposing employees to a fall hazard:
- On or about February 13,2014, on the approximate 4th floor of the Fluid Catalytic Cracking Unit (FCCU) a hole measuring approximately 3 inches in diameter was not guarded.
- On or about April 4, 2014, on the approximate 8th floor of the FCCU a hole measuring approximately 4 inches by 4 inches was not guarded.
Pursuant to 29 CFR 1903.19, within ten (10) calendar days of the date of this citation, the employer must submit documentation describing the steps that all floor holes are guarded.
Citation 1 Item 2
Type of Violation: Serious; $4,400
29 CFR 1910.23(a)(8): Every floor hole into which persons can accidentally walk were not guarded.
The employer does not ensure that all floor holes are guarded, exposing employees to a fall hazard:
- On or about February 13,2014, on the approximate 4th floor of the Fluid Catalytic Cracking Unit (FCCU) a hole measuring approximately 3 inches in diameter was not guarded.
- On or about April4, 2014, on the approximate 8th floor of the FCCU a hole measuring approximately 4 inches by 4 inches was not guarded.
The employer must submit documentation describing the steps that all floor holes are guarded.
Citation 2 Item 1
Type of Violation: Repeat; $33,000
Section 5(a)(1) of the Occupational Safety and Health Act of 1970: The employer did not furnish employment and a place of employment which were free from recognized hazards that were causing or likely to cause death or serious physical hartm to employees who were exposed to the hazard of burns from contact with hot equipment surfaces:
The employer does not ensure that each employee is protected from contact with hot surfaces on process equipment. This violation was observed on or about April 14, 2014, on the Mezzanine level of the Fluid Catalytic Cracking Unit (FCCU) where employees were exposed to skin burns from contact with the FCCU Spent Cat Slide Valves (007-VA-H2 and 007-VA-H3) equipment with surface temperatures of 730 degrees F, and which were not insulated or otherwise guarded to prevent bodily contact.
Business was previously cited for a violation of this occupational safety and health standard Section 5 (a)(l ), which was contained in OSHA inspection number 312380512, citation number 01, item number 003 and was affirmed as a final order on 09/23/2010.
Among other methods, one feasible and acceptable abatement method to correct the hazards identified, would be to install guardrails, as had been done on other levels of the unit, to prevent bodily contact with hot surfaces.
Citation 2 Item 2
Type of Violation: Repeat; $33,000
Section 5(a)(1) of the Occupational Safety and Health Act of 1970: The employer did not furnish employment and a place of employment which were free from recognized hazards that were causing or likely to cause death or serious physical harm to employees in that employees were exposed to tripping hazards when walking/working on multiple levels of the Fluid Catalytic Cracking Unit (FCCU) structure where grating was detached and not level:
The employer does not ensure that walking/working surfaces are level and free from tripping hazards.
This violation was observed on or about February 13,2014, on multiple levels of the FCCU structure where employees were exposed to tripping hazards where grating and metal decking was detached, not level, and contained holes.
Business was previously cited for a violation of this occupational safety and health standard Section 5 (a)(1 ), which was contained in OSHA inspection number 312380512, citation number 01, item number 004 and was affirmed as a final order on 09/23/2010. Among other methods, one feasible and acceptable abatement method to correct the hazards identified, would be to repair the floor levels with patches and welding techniques when they become detached.
Citation 2 Item 3
Type of Violation: Repeat; $3,8500
29 CFR 1910.23(a)(2): Every ladder way floor opening or platform was not guarded by a standard railing, or swinging gate, or so offset that a person cannot walk directly into the opening.
The employer does not ensure that ladder way floor openings are guarded by a standard railing, or equivalent means, to prevent employees from falling through the openings. This violation was observed on or aboutApril4, 2014, on multiple levels of the FCCU structure where employees
walking/working in the vicinity of unguarded ladder way opening were exposed to fall hazards to the concrete and equipment surfaces below.
Pursuant to 29 CFR 1903.19, within ten (10) calendar days of the date of this citation, the employer must submit documentation describing the steps that is taking to ensure all ladder way openings are guarded.
Business was previously cited for a violation of this occupational safety and health standard 29 CFR 1910.23 ( a)(2), which was contained in OSHA inspection number 312380512, citation number 01, item number 005 and was affirmed as a final order on 09/23/2010.
Citation 2 Item 4
Type of Violation: Repeat; $27,500
29 CFR 1910.23(c)(l): Open-sided floors or platforms four feet or more above adjacent floor or ground level were not guarded with standard railings (or equivalent) on all open sides; and toe boards where hazard exposures exist below:
The employer does not ensure that open-sided floors and platforms are provided with standard railing or equivalent means of guarding:
- This violation was observed on or about February 13, 2014, in the FCCU where employees walking/working on the first floor near the Regenerator B Feed Line (catalyst drop out line 007-CAlB) that had a damaged toe board and did not have guardrails around the Line.
- This violation was observed on or about February 13, 2014, in the FCCU where employees walking/working on a floor without guardrails around the Regenerator A Feed Line (catalyst drop out line 007-CA-IA).
The employer must submit documentation describing the steps that is taking to ensure guardrails are erected along all open-sided floors and platforms.
Business was previously cited for a violation of this occupational safety and health standard 29 CFR 1910.23 (c)(1), which was contained in OSHA inspection number 312380512, citation number 01, item number 006 a and was affirmed as a final order on 09/23/2010.
Citation 2 Item 5
Type of Violation: Repeat; $38,500
29 CFR 1910.307(c): Equipment, wiring methods, and installations of equipment in hazardous (classified) locations were not intrinsically safe, approved for the hazardous (classified) location, or safe for the hazardous (classified) location.
The employer does not ensure hazardous (classified) locations contain only equipment that is maintained in an intrinsically safe condition or otherwise safe for the location:
- The violation was observed on or about February 4, 2014, on the approximate 8th floor of the FCCU structure, the employer did not ensure the cover and light bulb of an intrinsically safe light fixture was in installed, exposing employees to fire and explosion hazards.
- The violation was observed on or about February 4, 2014, on the approximate 8 1/2 floor of the FCCU structure, the employer did not ensure the cover of an intrinsically safe light fixture was in installed, exposing employees to fire and explosion hazards.
- The violation was observed in the Fluidized Catalytic Cracking Unit (FCCU) old oxygen analyzer room on or about February 13,2014 where the electrical boxes were left open exposing spark producing wiring and electrical connections that exposed employees to fire and explosion hazards.
The employer must submit documentation describing the steps that is taking to ensure that hazardous locations are equipped with safe electrical equipment and installations.
Business was previously cited for a violation of this occupational safety and health standard 29 CFR 1910.307 (c), which was contained in OSHA inspection number 312380512, citation number 01, item number 35 and was affirmed as a final order on 09/23/2010.
The citations can be viewed at: http://www.osha.gov/ooc/citations/HollyRefiningandMarketing958671_080114.pdf*.